Electrical differential locker with eddy current sensor

ABSTRACT

An actuator assembly including a housing. The housing having an actuator component, an armature, and at least a portion of a sensor disposed therein. The armature is selectively positionable between a first position and a second position. The sensor includes at least one sensing element disposed within the housing adjacent to the armature. The sensing element has a physical property which varies based upon a position of the armature within the housing.

CROSS REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. Non-Provisional patent application Ser. No. 16/225,361, entitled “ELECTRICAL DIFFERENTIAL LOCKER WITH EDDY CURRENT SENSOR”, and filed on Dec. 19, 2018. U.S. Non-Provisional application Ser. No. 16/225,361 claims priority to U.S. Provisional Application No. 62/609,439, entitled “ELECTRICAL DIFFERENTIAL LOCKER WITH EDDY CURRENT SENSOR”, and filed on Dec. 22, 2017. The entire contents of each of the above-listed applications are hereby incorporated by reference for all purposes.

TECHNICAL FIELD

The subject matter of the embodiments described herein relates generally to an axle assembly and means of torque conveyance and, more particularly, to a differential apparatus with an eddy current sensor for the axle assembly.

BACKGROUND

Axle assemblies in vehicle drivetrains are known to employ a differential apparatus to transmit torque from a power source to vehicle wheels. The differential apparatus permits an outer drive wheel to rotate at a greater velocity than an inner drive wheel when operating a vehicle through a turn, and the differential apparatus divides the power between the connected vehicle wheels.

A conventional differential apparatus is drivingly engaged with a drive pinion, which is turned by a driveshaft connected to the power source. The drive pinion is meshed with a ring gear attached to a differential case. Differential pinions are mounted on the opposite ends of a spider shaft located through the differential case. The differential pinions are meshed with side gears connected to axle half shafts coupled with one or more wheels.

When both wheels have equal traction, the pinion gears do not rotate on the spider shaft because the input force of the pinion gears is divided equally between the two side gears. When the vehicle is operated through a turn, the inner wheel slows down and the associated side gear also slows down, while the outer wheel and associated side gear speed up.

A well-known disadvantage of an axle assembly utilizing the differential apparatus occurs when one wheel is unintentionally stationary, and all of the power can only be transferred to the remaining movable wheel. Limited-slip and locking differentials were developed to overcome this disadvantage. In limited-slip differentials, driving force is provided to the wheel with the most traction before the other wheel begins to slip. Limited-slip differentials typically operate with selectively activated clutches. Locking differentials operate similarly to limited-slip differentials, except that when the vehicle wheels are rotating at different speeds the differential locks the axle half shafts together to rotate as a unitary shaft.

In conventional locking differentials, the differential apparatus is locked utilizing a device to engage a locking gear with the differential. This locking gear militates against differentiation, which militates against independent movement of the two axle half shafts. Known designs are disadvantaged by a locking gear that may not immediately engage with the differential apparatus, leading to uncertainty regarding the locked state of the differential apparatus.

In view of the disadvantages of the known designs, it would be desirable to remove the need for a magnet and a follower plate, thereby reducing cost, weight and complexity. It would also be desirable to use a non-contact type sensor to prevent wear. In addition, it would be desirable to know the exact position of the locking gear at all times.

SUMMARY

In concordance and agreement with the present disclosure, an axle assembly including a differential apparatus and an actuator assembly having a sensor which minimizes cost, weight, and complexity while enhancing durability and accuracy, has surprisingly been discovered.

In one embodiment, an actuator assembly, comprises: a housing; an actuator component disposed within the housing; an armature disposed within the housing, the armature selectively positionable between a first position and a second position; and a sensor including a first sensing element disposed within the housing adjacent to the armature, wherein a physical property of the first sensing element varies based upon a position of the armature.

In another embodiment, a method of determining a state of a differential apparatus, comprising the steps of: providing an axle assembly including a differential apparatus and an actuator assembly coupled to the differential apparatus, wherein the differential apparatus includes a locking gear, and wherein the actuator assembly includes a housing having an actuator component, an armature, and a sensor disposed therein, wherein the armature is selectively positionable between a first position and a second position, wherein the sensor includes a first sensing element disposed within the housing adjacent to the armature, and wherein a physical property of the first sensing element varies based upon a position of the armature; measuring the physical property of the first sensing element; transmitting the measured physical property of the first sensing element from the sensor to a controller; determining a position of the armature based upon the measured physical property of the first sensing element; and determining the state of the differential apparatus based upon the position of the armature.

Aspects of certain embodiments, the sensor is an eddy current sensor.

Aspects of certain embodiments, the armature is drivingly coupled to a differential apparatus.

Aspects of certain embodiments, the actuator assembly further comprises a spacer at least partially disposed within the housing.

Aspects of certain embodiments, the actuator assembly further comprises a controller coupled to the housing, wherein the controller is in electrical communication with the sensor.

Aspects of certain embodiments, the first sensing element is disposed between the armature and housing.

Aspects of certain embodiments, the first sensing element is disposed between the armature and the actuator component.

Aspects of certain embodiments, the first sensing element is disposed il”) a recess formed in the housing.

Aspects of certain embodiments, the actuator assembly further comprises a second sensing element disposed within the housing adjacent to the armature.

Aspects of certain embodiments, the sensor includes an array of at least one of the first sensing elements and the second sensing elements.

Aspects of certain embodiments, at least one of the first sensing element and the second sensing element is a coil.

Aspects of certain embodiments, a physical property of the second sensing element varies based upon a position of the armature.

Aspects of certain embodiments, the physical property of at least one of the first sensing element and the second sensing element is inductance.

Aspects of certain embodiments, the method further comprises the step of: determining a position of the locking gear of the differential apparatus based upon the position of the armature.

Aspects of certain embodiments, the method further comprises the steps of: measuring the physical property of the second sensing element; transmitting the measured physical property of the second sensing element from the sensor to the controller; and determining the position of the armature based upon the measured physical property of at least one of the first sensing element and the second sensing element.

Aspects of certain embodiments, the method further comprises the step of: differentiating between the inductance of the first and second sensing elements to compensate for a variation in a radial position of the armature.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the subject matter of the embodiments described herein, will become readily apparent to those skilled in the art from a reading of the following detailed description of the embodiments when considered in the light of the accompanying drawings in which:

FIG. 1 is a schematic illustration of a vehicle according to an embodiment of the presently disclosed subject matter;

FIG. 2 is side perspective view of an axle assembly schematically depicted in FIG. 1 according to an embodiment of the presently disclosed subject matter;

FIG. 3 is rear perspective view of the axle assembly shown in FIG. 2, wherein a portion of a carrier housing has been removed to show a differential apparatus and an actuator assembly coupled thereto;

FIG. 4 is a top plan view, partially in section, of the axle assembly shown in FIGS. 2-3, wherein the portion of the carrier housing has been removed to show a propeller shaft, a pinion gear, the differential apparatus, and the actuator assembly;

FIG. 5 is a top plan view, partially in section, of the differential assembly and the actuator assembly coupled thereto according to the embodiment shown in FIG. 4;

FIG. 6 is a top plan view, partially in section, of a differential assembly and an actuator assembly coupled thereto according to another embodiment of the presently disclosed subject matter;

FIG. 7 is a top plan view, partially in section, of a differential assembly and an actuator assembly coupled thereto according to another embodiment of the presently disclosed subject matter; and

FIG. 8 is a side perspective view of an actuator assembly according to yet another embodiment of the presently disclosed subject matter.

DETAILED DESCRIPTION

It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

Locking differentials are utilized in applications across multiple industries including automotive, aerospace, industrial automation equipment, and instrumentation applications. In one embodiment, the subject matter disclosed herein may be utilized in the operation of an all-wheel drive vehicle.

As illustrated in FIG. 1, in an embodiment, a vehicle 10 includes a motor 12 (e.g. an internal combustion engine) driveably connected with a transmission 14. An output of the transmission 14 is driveably connected with an axle assembly 100 via a propeller shaft 16. The axle assembly 100 is depicted as a rear axle assembly; however, persons skilled in the relevant art will recognize that the axle assembly 100 described herein may be located as a front axle, a rear axle, or one of a tandem axle pair.

Embodiments of axle assembly 100 are described below. The axle assembly 100 may be utilized with an all-wheel drive vehicle, a pure electric vehicle and a hybrid four-wheel-drive vehicle where the front axle is driven by the motor 12, and the rear axle includes the axle assembly 100 (or vice versa). In still other embodiments, the axle assembly 100 may be utilized in a hybrid commercial vehicle (not depicted) comprising a tandem axle in which the front tandem axle is driven by an internal combustion engine, and the rear tandem axle includes one of the axle assembly 100 (or vice versa). The axle assembly 100 may have applications in commercial vehicles, both light duty and heavy duty vehicles, and for passenger, off-highway, and sport utility vehicles. Additionally, the axle assembly 100 described herein may be adapted for use in front and/or rear driving axles, and in steerable and non-steerable axles. It would be understood by one of ordinary skill in the art that the axle assembly 100 also may have industrial, locomotive, military, agricultural, and aerospace applications.

In certain embodiments, the axle assembly 100 may employed in an integrated drive system. The axle assembly 100 may include an electric motor (not depicted) (e.g., electromotor) coupled with a power source (not depicted). The electric motor may be a permanent magnet synchronous machine comprising a stator disposed concentrically about a rotor. The axle assembly 100 may additionally comprise an inverter (not depicted) for converting direct current to alternating current when the electric motor is utilized to drive the vehicle, and for converting alternating current to direct current when the vehicle decelerates. The electric motor may be referred to herein as a motor-generator. Further, the axle assembly 100 may include cooling fluid (not depicted) such as, but not limited to, automatic transmission fluid or axle oil integrated with the axle assembly 100 for cooling the electric motor and the inverter. In another embodiment (not depicted), the cooling fluid for the electric motor and the inverter may not be integrated with the axle oil. The axle assembly 100 may have either a co-axial or off-axis layout where the axle shaft connecting the wheel to the differential does not pass through the center or the motor but rather parallel to the motor axis.

The axle assembly 100 depicted in FIG. 2 includes a carrier housing 101. As more clearly illustrated in FIG. 4, the pinion gear 18, shown in FIG. 1, and at least a portion of the propeller shaft 16 are rotatably supported within the carrier housing 101 via one or more bearings 103.

Now referring to FIGS. 3 and 4, the axle assembly 100 includes a differential mechanism comprising a differential case 102 mounted for rotation within the carrier housing 101. The pinion gear 18 is in meshed engagement with a ring gear 104, and conveys torque to the differential case 102 via the ring gear 104. The ring gear 104 may be integrally formed with the differential case 102, or may be coupled with the differential case 102 via welding or mechanical fasteners.

The differential case 102 is mounted for rotation within the carrier housing 101 via a pair of bearings 105. The bearings 105 are disposed about a first and second trunnion 106, 108, respectively, on opposing portions of the differential case 102. In an embodiment, the differential case 102 may be produced via the process of flow forming a metallic material such as, but not limited to, steel, premium carbon steel, aluminum, and aluminum alloys.

With reference to FIGS. 4 and 5, a first pinion shaft 110 is disposed in the differential case 102. In an embodiment, the first pinion shaft 110 extends through the differential case 102 and is coupled at its ends in two opposing apertures 112 through the differential case 102. First and second pinion gears 114, 116, are mounted on each end of the first pinion shaft 110, respectively. In certain embodiments, as more clearly illustrated in FIG. 5, a second pinion shaft 118 extends into the differential case 102 transverse the first pinion shaft 110 and is coupled at its ends with the differential case 102. A third pinion gear 120 and a fourth pinion gear (not depicted) are rotatably supported on the ends of the second pinion shaft 118. In other embodiments, not shown, the pinion gears 120, (not depicted) are supported by a unitary cross pin.

The pinion gears 114,116, 120, (not depicted) are meshed with a first side gear 122 and a second side gear 124 within the differential case 102. The side gears 122, 124 comprise radially inward projecting splines 130, 132, respectively, to engage axle half shafts (not depicted) or stub shafts (not depicted). The differential case 102 comprises openings 126, 128 through the differential case trunnions 106, 108 to accommodate the axle half shafts coupled with the side gears 122, 124. The axle half shafts are inserted into the openings 126, 128 and into the side gears 122, 124 where they engage the internal splines 130, 132 of the side gears 122, 124, respectively. In an embodiment, the axle half shafts are secured in their position in the axle assembly 100 by c-clips (not depicted) inserted into grooves in the axle half shafts.

As illustrated in FIGS. 3-5, an actuator assembly 140 is mounted on the differential case trunnion 108. The actuator assembly 140 is coupled with the differential case 102 such that the actuator assembly 140 is fixed against rotation relative to the differential case 102. Referring now to FIG. 5, the actuator assembly 140 comprises a housing 142. In an embodiment, the housing 142 may have an annular geometry such that an inner portion of the housing 142 is coupled with a sleeve 144. The sleeve 144 is coupled with the differential case trunnion 108. An actuator component 146

such as an electromagnetic coil, for example, is disposed within the housing 142. The actuator component 146 is in electrical communication with a power source (not depicted), such as, but not limited to, a battery. The actuator component 146 may also be in communication with a controller 147. In an embodiment shown in FIG. 5, the controller 147 may be mounted to an inboard portion of the housing 142. In another embodiment shown in FIG. 6, the controller 147 may be mounted to an outboard surface of the housing 142. In still another embodiment shown in FIG. 7, the controller 147 may be mounted to a radially outer surface of the housing 142.

A generally hollow-cylindrical armature 148 is disposed in the housing 142, radially between the actuator component 146 and the inner portion of the housing 142. In an embodiment, the armature 148 does not rotate relative to the housing 142. The armature 148 comprises a ferromagnetic material. Disposed axially adjacent to the armature 148, on an inboard side thereof, is an annular spacer 150. The annular spacer 150 may be comprised of a polymeric material. In an embodiment, as illustrated in FIG. 5, a pressure plate 152 may be positioned axially adjacent to an inboard side of the spacer 150. However, those skilled in the relevant art will recognize that the actuator assembly 140 may be designed without the pressure plate 152. Further, a locking gear 154 is disposed axially between the spacer 150 and the side gear 124. The locking gear 154 defines a plurality of teeth 156 located on an axially inboard surface thereof. The locking gear teeth 156 selectively engage complimentary teeth 158 defined by an axially outboard surface of the side gear 124.

The locking gear 154 is axially slideable between a first position, illustrated in FIG. 5, where the locking gear 154 is disengaged from the side gear 124, and a second position (not depicted) where the locking gear 154 is engaged with the side gear 124. The locking gear 154 rotates with the differential case 102. In an embodiment, the locking gear 154 comprises generally axial protrusions 160 disposed through openings 162 in the differential case 102. The mechanical interaction between the locking gear protrusions 160 and the differential case openings 162 causes the locking gear 154 to rotate with the differential case 102.

In an embodiment, the armature 148 is coupled with the locking gear 154. In one embodiment, the armature 148 and the locking gear 154 may be coupled with the spacer 150, such that they move axially as a single unit. The armature 148 and the locking gear 154 may be coupled with the spacer 150 via a snap-fit connection, for example. Coupling the armature 148 and the locking gear 154 prevents the armature 148 from being vibrated into a disengaged position while the locking gear 154 remains in an engaged position. In an embodiment, the locking gear 154 may remain temporarily engaged even when the armature 148 is in a disengaged position, due to the key-stone shape of the differential case openings 162 creating an axial force on the locking gear 154 during torque transmission.

A biasing member 164 is disposed axially between the locking gear 154 and the side gear 124. In an embodiment, the locking gear 154 defines a groove 166 located in an inboard surface thereof. The locking gear groove 166 is aligned with a groove 168 defined in an outboard surface of the side gear 124. The biasing member 164 may be at least partially located within the grooves 166, 168. The biasing member 164 may be, but is not limited to, one or more springs, one or more wave springs, or one or more Bellville-type washers. In an embodiment, the locking gear groove 166 and the side gear groove 168 are annular in geometry.

To lock the differential mechanism of the axle assembly 100, in the second position of the locking gear 154, a signal from the controller 147 causes electricity, which may also be referred to herein as an excitation voltage, to be supplied to the actuator component 146. The energized actuator component 146 generates a magnetic flux. The magnetic flux of the actuator component 146 causes the armature 148 to move in an axial direction and drive the locking gear 154 into engagement with the side gear 124, thereby compressing the biasing member 164. To return the locking gear 154 to the first position, and unlock the differential mechanism, the controller 147 causes the supply of electricity to the actuator component 146 to be interrupted or reduced. The termination or reduction in the energization of the actuator component 146 enables the biasing member 164 to urge the locking gear 154 in an axial outboard direction and disengage the side gear 124. When the actuator component 146 is energized, the locking gear 154 may not immediately engage the side gear 124. This time delay may lead to an uncertainty regarding the locked/unlocked state of the differential mechanism. To determine the axial position of the locking gear 154, and therefore the locked/un-locked state of the differential mechanism, a sensor 170 may be utilized. Various types of sensors may be utilized for the sensor 170 such as an eddy current sensor, for example.

In an embodiment, the sensor 170 may comprise a sensing element 172 having certain physical properties (e.g. an inductance) disposed concentrically about a portion of the actuator assembly 140. The sensing element 172 shown has a generally disc shape. It is understood, however, that the sensing element 172 may have any shape and size as desired such as a substantially planar plate, for example. As illustrated in FIG. 5, the sensor 170 includes the sensing element 172 disposed in an annular recess defined by in the inner portion of the housing 142 radially between

the inner portion of the housing 142 and the armature 148. In another embodiment, as illustrated in FIG. 6, the sensor 170 includes the sensing element 172 disposed radially between the actuator component 146 and the armature 148.

The inductance of the sensing element 172 varies based upon a position of the armature 148 and is sensitive to a percentage of the armature 148 which overlaps the sensor 170. The radial distance between the sensing element 172 and the armature 148, ideally, remains constant. Actuation of the armature 148 moves the armature 148 axially parallel to the sensor 170 causing a change in the inductance of the sensing element 172. The inductance in the sensing element 172 is proportional to the axial position of the armature 148. The inductance in the sensing element 172 is measured and transmitted to the controller 147 which utilizes the measured inductance, i.e., conditions the sensor 170 output signal, to determine the locked/un-locked state of the locking gear 154 and the differential mechanism.

In an embodiment, as illustrated in FIG. 7, the sensor 170 may comprise a first sensing element 172 located radially between the inner portion of the housing 142 and the armature 148, and a second sensing element 174 located radially between the armature 148 and the actuator component 146. In this embodiment, utilizing two sensing elements 172, 174 disposed concentric with the armature 148 removes error created by any variation in the radial distance between the armature 148 and the sensing elements 172,174. As one portion of the armature 148 moves closer to the first sensing element 172, a second portion of the armature 148 moves away from the second sensing element 174. Differentiating between the inductance in the first and second sensing elements 172, 174 compensates for the noise added to the signal of the sensor 170 from variations in the radial position of the armature 148.

In any of the embodiments described herein, the sensing elements 172, 174 may comprise a flexible material to facilitate the contour thereof about the housing 142 when the sensing elements 172, 174 are embedded within the actuator assembly 140. In an embodiment, the sensing elements 172, 174 may comprise a flexible printed circuit board (“PCB”).

In another embodiment, as illustrated in FIG. 8, the sensor 170 may include a sensing element 176 which comprises a partial disc, rather than a full disc such as the sensing element 172. The sensing element 176 may be coupled with a portion of the housing 142 located on either radial side of the armature 148. Similar to the embodiment described with regard to FIG. 7, the actuator assembly 140 may comprise an array of sensing elements 176, such that differentiating the inductance therebetween reduces the noise of the sensor signal from variations in the radial position of the armature 148. It should be appreciated that the array of sensing elements 176 may employ various sizes, shapes, and spacing of the sensing elements 176 as desired.

The embodiments of the sensor 170 described above may also be utilized with other clutch types, including, but not limited to, a worm gear type clutch (not depicted) and a clutch including a fork (not depicted).

From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of the subject matter of the embodiments described herein and, without departing from the spirit and scope thereof, can make various changes and modifications to the embodiments to adapt them to various usages and conditions. 

1. A system for a vehicle, comprising: a pressure plate configured to lock a differential; and an actuator assembly, comprising: a housing; an actuator coil disposed within the housing; an armature disposed within the housing, the armature selectively positionable between a first position and a second position to actuate the pressure plate; a sensor including a first sensing element, wherein a physical property of the first sensing element varies based upon a position of the armature or pressure plate, wherein the sensor is not a full disc; and a controller in electrical communication with the sensor, the controller coupled with a portion of the housing and extending radially outward past an outermost radial surface of the housing.
 2. The system according to claim 1, wherein the sensor is an eddy current sensor.
 3. The system according to claim 1, wherein the armature is an annular.
 4. The system according to claim 1, further comprising the differential, the differential housed in a differential case.
 5. The system according to claim 1, wherein the controller extends toward a central axis of the actuator radially inward past the outmost radial surface of the housing.
 6. The actuator assembly according to claim 1, wherein the first sensing element is disposed between the armature and housing.
 7. The actuator assembly according to claim 1, wherein the first sensing element is disposed between the armature and the coil.
 8. The actuator assembly according to claim 1, wherein the first sensing element is disposed in a recess formed in the housing.
 9. The actuator assembly according to claim 1, further comprising a second sensing element disposed within the housing adjacent to the armature.
 10. The actuator assembly according to claim 9, wherein the sensor includes an array of at least one of the first sensing elements and the second sensing elements.
 11. The actuator assembly according to claim 1, wherein the first sensing element is a coil.
 12. The actuator assembly according to claim 9, wherein a physical property of the second sensing element varies based upon a position of the armature.
 13. The actuator assembly according to claim 12, wherein the physical property of at least one of the first sensing element and the second sensing element is inductance.
 14. An axle assembly for a vehicle, comprising: an axle shaft; an electric motor coupled with a power source; a differential assembly; and an inverter, wherein the axle assembly has a co-axial or off-axis layout where the axle shaft connecting a wheel to the differential assembly does not pass through a center of the electric motor but rather parallel to a motor axis, the differential assembly including: a pressure plate configured to lock a differential; and an actuator assembly, comprising: a housing; an actuator coil disposed within the housing; an armature disposed within the housing, the armature selectively positionable between a first position and a second position to actuate the pressure plate; a sensor including a first sensing element, wherein a physical property of the first sensing element varies based upon a position of the armature or pressure plate, wherein the sensor is not a full disc; and a controller in electrical communication with the sensor, the controller coupled with a portion of the housing and extending radially outward past an outermost radial surface of the housing.
 15. The axle assembly according to claim 14, wherein the sensor is an eddy current sensor.
 16. The axle assembly according to claim 14, wherein the armature is an annular.
 17. The axle assembly according to claim 14, wherein the controller extends toward a central axis of the actuator radially inward past the outmost radial surface of the housing.
 18. The axle assembly according to claim 14, wherein the first sensing element is disposed between the armature and housing. 